Generac Power Systems 5411, 5412, 5413, 5415, 5414, 5410 manual Problem 10 7.5A F1 Fuse Blowing, Yes

Page 37

Section 6

TROUBLESHOOTING FLOWCHARTS

Problem 10 – 7.5A (F1) Fuse Blowing

INSTALL NEW 7.5 AMP FUSE

FUSE BLOWS UPON

INSTALLATION

CHECK THAT FUSE

HOLDER IS NOT

GROUNDED

PASS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FAIL

 

REPLACE HOLDER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

REMOVE WIRE 15

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FROM JI HARNESS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONNECTOR.

 

 

 

 

 

 

 

 

 

 

 

 

 

DOES FUSE BLOW?

 

 

 

 

 

REPLACE

NOTE A:

 

 

 

 

 

 

(SEE NOTE A)

 

NO

 

 

 

 

 

 

 

 

 

 

 

PRINTED CIRCUIT

Disconnect harness from engine controller

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BOARD

circuit board.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Gently bend red tabs outward and remove red

 

 

 

 

 

 

 

YES

 

 

 

 

 

 

 

 

plastic pin guide.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Using a small flathead screwdriver, slide black

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

retainer tabs out away from Wire 15 pin

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(orange).

 

 

 

 

 

 

 

 

 

CHECK WIRE 15

 

 

 

 

 

Gently push pin out of harness and pull wire

 

 

 

 

 

 

 

 

FOR SHORT TO

 

 

 

out from back of plug, noting it’s location for

 

 

 

 

 

 

 

 

GROUND

 

 

 

reinstallation later.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace red pin guide and plug J1 harness

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

back into engine controller circuit board.

FUSE IS GOOD BUT

 

 

 

 

 

 

CHECK REMOTE

 

Replace fuse.

 

 

 

 

 

 

 

 

If fuse does not blow, replace engine controller

BLOWS WHEN START-

 

 

 

 

 

 

HARNESS WIRE 15

 

 

 

 

 

 

 

 

circuit board.

 

STOP SWITCH IS

 

 

 

 

 

 

FOR SHORT TO

 

 

 

 

 

 

 

 

 

If fuse still blows, continue to next section of

 

PRESSED

 

 

 

 

 

 

 

 

GROUND

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Problem 10 flow chart.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PERFORM RESISTANCE TESTS ON FUEL PUMP, FUEL SOLENOID,

DISCONNECT JI HARNESS

 

 

 

 

YES

 

CHOKE HEATER AND REMOTE HARNESS WIRE 14 (SEE * BELOW).

FROM ENGINE CONTROL-

 

 

 

 

 

ALSO CHECK WIRE 14 TO EACH COMPONENT FOR SHORT TO GROUND.

LER CIRCUIT BOARD AND

 

 

 

 

 

 

 

 

CHECK WIRE 14 FOR

 

 

 

* CHECK FOR CONTINUITY TO FRAME GROUND. CONNECT ONE TEST

SHORT TO GROUND.

 

 

 

 

 

 

LEAD TO THE POSITIVE WIRE FOR EACH COMPONENT. CONNECT THE

IS CONTINUITY PRESENT?

 

 

 

 

 

 

OTHER TEST LEAD TO FRAME GROUND. RESISTANCE SHOULD BE

 

 

 

 

 

 

 

 

 

 

MEASURED. IF CONTINUITY “0” IS MEASURED TO GROUND, THAT

 

 

 

 

 

COMPONENT OR WIRE IS SHORTED.

 

 

 

 

 

ALSO, REFER TO THE INDIVIDUAL TESTS FOR EACH COMPONENT IN

 

 

 

 

 

SECTION 7, UNDER “PROCEDURE – SHORT TO GROUND”.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NO

REPLACE COMPONENT OR WIRE

CHECK CHOKE SOLENOID AND STARTER CONTACTOR RELAY

STARTER CONTACTOR RELAY PIN LOCATION J1-1 TEST TO GROUND

CHOKE SOLENOID PIN LOCATION J1-2

TEST TO GROUND

FAIL

FAIL

CHECK WIRE 56 FOR SHORT TO GROUND

CHECK WIRE 90 FOR SHORT TO GROUND

REPAIR OR

REPLACE COMPONENT OR WIRE

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Electromagnetic Fields MagnetismElectromagnetic Induction More Sophisticated AC Generator Simple AC GeneratorGenerator Operating Diagram Generator AC Connection System Field BoostConnection for 120 Volts Only Stator Assembly Rotor AssemblyExcitation Circuit Components Brush HolderDescription Crankcase BreatherControl Panel Components Control Panel Component IdentificationEffects of Dirt and Moisture Cleaning the GeneratorInsulation Resistance Testers Drying the GeneratorStator Insulation Resistance Testing Stator Insulation Testing Rotor InsulationTesting Rotor Insulation MegohmmeterVOM MetersMeasuring AC Voltage Measuring DC VoltageMeasuring Resistance Measuring CurrentOhm’s Law Electrical UnitsOperational Analysis IntroductionCircuit Condition Cranking Circuit Condition Running Circuit Condition Shutdown Recommended Battery BatteryBattery Cables Printed Circuit BoardAmp Fuse Start-Stop SwitchStarter Contactor Relay Starter Motor Start-Stop SwitchProblem 1 Voltage & Frequency Are Both High or Low If Problem Involves AC OutputTest Troubleshooting Flowcharts Proble 5 Priming Function Does Not Work Gasoline Models Problem 6 Engine Will Not Crank Test 26 Check Test 20 Check Check Fuel Wire 14 Power Good Troubleshooting Flowcharts Problem 8 Engine Starts Hard and Runs Rough Gasoline Units Problem 8 Engine Starts Hard and Runs Rough LP Units LOW OIL Pressure Flashes on SW1 LED YES Problem 10 7.5A F1 Fuse BlowingTest 1 Check No-Load Voltage Frequency ProcedureTest 2 Check Stepper Motor Control DiscussionTest 4 Fixed Excitation Test/Rotor Amp Draw Six Pin J2 Connector Wire ColorsFixed Excitation Test, Step B Test 6 Test Stator DPE Winding Test 5 Check Field BoostStator Excitation Winding Test 7 Check Sensing Leads / Power WindingsTest 8 Check Brush Leads Stator Power Winding LeadsTest 9 Check Brushes & Slip Rings Test 10 Check Rotor AssemblyTest 11 Check Main Circuit Breaker SchematicTest 12 Check Load Voltage Frequency Test 13 Check Load Watts AmperageTest 15 Check Fuel Pump Test 14 Try Cranking the EngineTest 18 Check Power Supply to Printed Circuit Board Test 17 Check Battery & CablesTest 16 Check 7.5 Amp Fuse Test 20 Check Start-Stop Switch Test 19 Check Continuity of WireTest 22 Check Starter Contactor Relay Test 21 Check Power Supply to WireTest 24 Check Starter Motor Test 23 Check Starter ContactorPinion Checking the PinionTools for Starter Performance Test Minimum rpm 4500 Maximum Amps To Carburetor GAS Test 25 Check Fuel Supply29. Fuel Regulator Test 26 Check Wire 14 Power SupplyTest 28 Check Fuel Solenoid Gasoline Models Test 27 Check WireTools RequiredTwo Ignition Testers Generac P/N 0C5969 Test 29 Check Ignition SparkTest 30 Check Spark Plugs Test 31 Check and Adjust Ignition Magnetos37. Setting Ignition Magneto Armature Air Gap Checking Flywheel Magnet Test 32 Check Valve AdjustmentFlywheel KEY Test 34 Check Choke Solenoid Test 33 Check CarburetionSolenoid Panel To ControlTest 36 Check Oil Pressure Switch Test 38 Test Oil Temperature Switch Test 37 Check Wire 86 for ContinuityTest 40 Test Choke Heater Test 39 Check Wire 85 for ContinuityTest 41 Check LPG Fuel Solenoid Section Exploded Views QTY Description Enclosure Drawing No G3881-C Enclosure Door Views Screw Plastite HI-LOW #10X3/8 Engine Accessories Drawing No G7718-B QTY Description 48,49 Square Head Plug Rotor & Stator Drawing No G3953-b NUT TOP Lock FL M8-1.25 Charts Nominal Resistances of Generator Windings at 68f Generator SpecificationsElectrical Data Electrical Data OG7515 REV. a

5410, 5414, 5415, 5413, 5411 specifications

Generac Power Systems has established itself as a leading manufacturer of backup power solutions, particularly known for its range of generators designed for both residential and commercial use. Among their noteworthy products are the Generac models 5412, 5411, 5413, 5415, and 5414. Each of these generators showcases innovative technologies and features that enhance reliability, efficiency, and ease of use.

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